VLTAquaDesignGuide(130R0337)

Design Guide

Contents

1. How to Read this Design Guide 3Copyright, Limitation of Liability and Revision Rights 3

Approvals 4

Symbols 4

Abbreviations 5

Definitions 5

2. Introduction to the VLT AQUA Drive 11Disposal Instructions 12

CE labeling 13

Air humidity 15

Aggressive Environments 15

Vibration and shock 16

VLT AQUA Controls 20

PID 22

General aspects of EMC 32

Galvanic isolation (PELV) 35

Ground leakage current 36

Control with brake function 36

Mechanical brake control 38

Extreme running conditions 38

Safe Stop Operation 40

3. VLT AQUA Selection 43General Specifications 43

Line Supply 3 x 200-240 V AC 43

Line Supply 3 x 380-480 V AC 47

Efficiency 55

Special Conditions 60

Purpose of derating 60

Automatic adaptations to ensure performance 63

Mechanical Dimension 64

Options and Accessories 65

Analog I/O option MCB 109 71

4. How to Order 77Ordering form 77

VLT AQUA Drive Design Guide Contents

MG.20.N2.22 - VLT is a registered Danfoss trademark. 1

Type Code String 78

Ordering Numbers 79

5. How to Install 83Mechanical Installation 83

Accessory Bag 83

Electrical Installation 85

Removal of Knockouts for Extra Cables 85

Access to Control Terminals 92

Electrical Installation, Control Terminals 93

Final Set-Up and Test 97

Final Set-Up and Test 97

Safe Stop Installation 99

Safe Stop Commissioning Test 100

Additional Connections 100

Installation of misc. connections 104

Safety 107

EMC-correct Installation 108

Residual Current Device 112

6. Application Examples 113

7. RS-485 Installation and Set-up 123RS-485 Installation and Set-up 123

FC Protocol Overview 126

Network Configuration 127

FC Protocol Message Framing Structure 127

Examples 133

Modbus RTU Overview 135

VLT AQUA with Modbus RTU 136

Modbus RTU Message Framing Structure 136

How to Access Parameters 141

Examples 142

Danfoss FC Control Profile 148

8. Troubleshooting 155

Index 162

Contents VLT AQUA Drive Design Guide

2 MG.20.N2.22 - VLT is a registered Danfoss trademark.

1. How to Read this Design Guide

1.1.1. Copyright, Limitation of Liability and Revision Rights

This publication contains information proprietary to Danfoss A/S. By accepting and using thismanual, the user agrees that the information contained herein will be used solely for operatingequipment from Danfoss A/S or equipment from other vendors, provided that such equipment isintended for communication with Danfoss equipment over a serial communication link. This pub-lication is protected under the copyright laws of Denmark and most other countries.

Danfoss A/S does not guarantee that a software program produced according to the guidelinesprovided in this manual will function properly in every physical, hardware or software environment.

Although Danfoss A/S has tested and reviewed the documentation within this manual,Danfoss A/S makes no warranty or representation, neither expressed nor implied, with respect tothis documentation, including its quality, performance or fitness for a particular purpose.

In no event shall Danfoss A/S be liable for direct, indirect, special, incidental or consequentialdamages arising from the use or the inability to use information contained in this manual, even ifadvised of the possibility of such damages. In particular, Danfoss A/S is not responsible for anycosts, including, but not limited to, those incurred as a result of lost profits or revenue, loss of ordamages to equipment, loss of computer programs, loss of data, the costs to substitute these, orany claims by third parties.

Danfoss A/S reserves the right to revise this publication at any time and to make changes to itscontents without prior notice or any obligation to notify former or present users of such revisionsor changes.

This design guide will introduce all aspects of your VLT AQUA Drive.

Available literature for the VLT AQUADrive

- The Instruction Manual MG.20.MX.YY provides the necessary information for getting thedrive up and running.

- Drive Design Guide MG.20.NX.YY contains all the technical information about the drive,customer design and applications.

- Programming Guide MG.20.0X.YY provides information on how to program and includescomplete parameter descriptions.

X = Revision numberYY = Language code

Danfoss Drives technical literature is also available online at www.danfoss.com/BusinessAreas/DrivesSolutions/Documentations/Technical+Documentation.

VLT AQUA Drive Design Guide 1. How to Read this Design Guide


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1.1.2. Approvals

1.1.3. Symbols

Symbols used in this guide.

NOTEIndicates something to be noted by the reader.

Indicates a general warning.

Indicates a high-voltage warning.

Indicates default setting

1. How to Read this Design Guide VLT AQUA Drive Design Guide


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1.1.4. Abbreviations

Alternating current ACAmerican wire gauge AWGAmpere/AMP AAutomatic Motor Adaptation AMACurrent limit ILIMDegrees Celsius CDirect current DCDrive Dependent D-TYPEElectro Magnetic Compatibility EMCElectronic Thermal Relay ETRdrive FCGram gHertz HzKilohertz kHzLocal Control Panel LCPMeter mMilli Henry Inductance mHMilliampere mAMillisecond msMinute minMotion Control Tool MCTNanofarad nFNewton Meters NmNominal motor current IM,NNominal motor frequency fM,NNominal motor power PM,NNominal motor voltage UM,NParameter par.Protective Extra Low Voltage PELVPrinted Circuit Board PCBRated Inverter Output Current IINVRevolutions Per Minute RPMSecond sTorque limit TLIMVolt V

1.1.5. Definitions

Drive:

IVLT,MAXThe maximum output current.

IVLT,NThe rated output current supplied by the adjustable frequency drive.

UVLT, MAXThe maximum output voltage.

Input:

Control commandYou can start and stop the connected motor usingthe LCP and the digital inputs.Functions are divided into two groups.Functions in group 1 have higher priority thanfunctions in group 2.

Group 1 Reset, Coasting stop, Reset and Coastingstop, Quick stop, DC braking, Stop and the"Off" key.

Group 2 Start, Pulse start, Reversing, Start reversing,Jog and Freeze output



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Motor:

fJOGThe motor frequency when the jog function is activated (via digital terminals).

fMThe motor frequency.

fMAXThe maximum motor frequency.

fMINThe minimum motor frequency.

fM,NThe rated motor frequency (nameplate data).

IMThe motor current.

IM,NThe rated motor current (nameplate data).

nM,NThe rated motor speed (nameplate data).

PM,NThe rated motor power (nameplate data).

TM,NThe rated torque (motor).

UMThe instantaneous motor voltage.

UM,NThe rated motor voltage (nameplate data).



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VLTThe efficiency of the adjustable frequency drive is defined as the ratio between the power outputand the power input.

Start-disable commandA stop command belonging to the group 1 control commands - see this group.

Stop commandSee Control commands.

References:

Analog ReferenceA signal transmitted to the analog inputs 53 or 54 can be voltage or current.

Bus ReferenceA signal transmitted to the serial communication port (FC port).

Preset ReferenceA defined preset reference to be set from -100% to +100% of the reference range. Selection ofeight preset references via the digital terminals.

Pulse ReferenceA pulse frequency signal transmitted to the digital inputs (terminal 29 or 33).

RefMAXDetermines the relationship between the reference input at 100% full scale value (typically 10 V,20 mA) and the resulting reference. The maximum reference value set in par. 3-03.

RefMINDetermines the relationship between the reference input at 0% value (typically 0V, 0 mA, 4 mA)and the resulting reference. The minimum reference value set in par. 3-02.



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Miscellaneous:

Analog InputsThe analog inputs are used for controlling various functions of the adjustable frequency drive.There are two types of analog inputs:Current input, 0-20 mA and 4-20 mAVoltage input, 0-10 V DC.

Analog OutputsThe analog outputs can supply a signal of 0-20 mA, 4-20 mA, or a digital signal.

Automatic Motor Adaptation, AMAAMA algorithm determines the electrical parameters for the connected motor at standstill.

Brake ResistorThe brake resistor is a module capable of absorbing the braking energy generated in regenerativebraking. This regenerative braking energy increases the intermediate circuit voltage, and a brakechopper ensures that the energy is transmitted to the brake resistor.

CT CharacteristicsConstant torque characteristics used for positive displacement pumps and blowers.

Digital InputsThe digital inputs can be used for controlling various functions of the adjustable frequency drive.

Digital OutputsThe drive features two solid state outputs that can supply a 24 V DC (max. 40 mA) signal.

DSPDigital Signal Processor.

Relay Outputs:The adjustable frequency drive features two programmable relay outputs.

ETRElectronic Thermal Relay is a thermal load calculation based on present load and time. Its purposeis to estimate the motor temperature.

GLCP:Graphical Local Control Panel (LCP102)

InitializingIf initializing is carried out (par. 14-22), the programmable parameters of the adjustable frequencydrive return to their default settings.

Intermittent Duty CycleAn intermittent duty rating refers to a sequence of duty cycles. Each cycle consists of an on-loadand an off-load period. The operation can be either periodic duty or non-periodic duty.



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LCPThe Local Control Panel (LCP) makes up a complete interface for control and programming of theadjustable frequency drive. The control panel is detachable and can be installed up to 9.8 ft (3meters) from the adjustable frequency drive, i.e. in a front panel by means of the installation kitoption.The local control panel is available in two versions:

- Numerical LCP101 (NLCP)

- Graphical LCP102 (GLCP)

lsbLeast significant bit.

MCMShort for Mille Circular Mil, an American measuring unit for cable cross-section. 1 MCM 0.00079in.2 (0.5067 mm2).

msbMost significant bit.

NLCPNumerical Local Control Panel LCP101

Online/Offline ParametersChanges to online parameters are activated immediately after the data value is changed. Changesto offline parameters are not activated until you enter [OK] on the LCP.

PID ControllerThe PID controller maintains the desired speed, pressure, temperature, etc. by adjusting the out-put frequency to match the varying load.

RCDResidual Current Device.

Set-upYou can save parameter settings in four set-ups. Change between the four parameter set-ups andedit one set-up while another set-up is active.

SFAVMSwitching pattern called Stator Flux oriented Asynchronous Vector Modulation (par. 14-00).

Slip CompensationThe adjustable frequency drive compensates for the motor slip by giving the frequency a supple-ment that follows the measured motor load, thus keeping the motor speed almost constant.

Smart Logic Control (SLC)The SLC is a sequence of user-defined actions executed when the associated user-defined eventsare evaluated as true by the SLC.



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Thermistor:A temperature-dependent resistor placed where the temperature is to be monitored (adjustablefrequency drive or motor).

TripA state entered in fault situations, such as when the adjustable frequency drive is subject to anovertemperature, or when the adjustable frequency drive is protecting the motor, process ormechanism. Restart is prevented until the cause of the fault has disappeared and the trip state iscancelled by activating reset or, in some cases, by being programmed to reset automatically. Tripmay not be used for personal safety.

Trip-LockedA state entered in fault situations when the adjustable frequency drive is protecting itself andrequires physical intervention, such as when it is subject to a short circuit on the output. A lockedtrip can only be cancelled by cutting off AC line power, removing the cause of the fault, andreconnecting the adjustable frequency drive . Restart is prevented until the trip state is cancelledby activating reset or, in some cases, by being programmed to reset automatically. The trip-lockfunction may not be used as a personal safety measure.

VT CharacteristicsVariable torque characteristics used for pumps and fans.

VVCplusCompared with standard voltage/frequency ratio control, Voltage Vector Control (VVCplus) im-proves the dynamics and the stability, both when the speed reference is changed and in relationto the load torque.

60 AVMSwitching pattern called 60 Asynchronous Vector Modulation (par. 14-00).

1.1.6. Power Factor

The power factor is the relation between I1and IRMS. Power factor =

3 U I1 COS3 U IRMS

The power factor for 3-phase control:=I1 cos1

IRMS=

I1IRMS

since cos1 = 1

The power factor indicates to which extent theadjustable frequency drive imposes a load onthe line supply.The lower the power factor, the higher theIRMS for the same kW performance.

IRMS = I21 + I

25 + I

27 + . . + I

2n

In addition, a high power factor indicates that the different harmonic currents are low.The adjustable frequency drive's built-in DC coils produce a high power factor, which minimizesthe imposed load on the line power supply.



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2. Introduction to the VLT AQUA Drive

2.1. Safety

2.1.1. Safety note

The voltage of the adjustable frequency drive is dangerous whenever connected toline power. Incorrect installation of the motor, adjustable frequency drive or serialcommunication bus may cause damage to the equipment, serious personal injury ordeath. Consequently, the instructions in this manual, as well as national and localrules and safety regulations, must be followed.

Safety Regulations1. The adjustable frequency drive must be disconnected from line power if repair work is to becarried out. Make sure that the line supply has been disconnected and that the necessary timehas passed before removing motor and line plugs.2. The [STOP/RESET] key on the control panel of the adjustable frequency drive does not dis-connect the equipment from line power and is thus not to be used as a safety switch.3. Correct protective grounding of the equipment must be established, the user must be protectedagainst supply voltage, and the motor must be protected against overload in accordance withapplicable national and local regulations.4. The ground leakage currents are higher than 3.5 mA.5. Protection against motor overload is set by par. 1-90 Motor Thermal Protection. If this functionis desired, set par. 1-90 to data value [ETR trip] (default value) or data value [ETR warning]. Note:The function is initialized at 1.16 x rated motor current and rated motor frequency. For the NorthAmerican market: The ETR functions provide class 20 motor overload protection in accordancewith NEC.6. Do not remove the plugs for the motor and line supply while the adjustable frequency drive isconnected to line power. Make sure that the line supply has been disconnected and that thenecessary time has passed before removing motor and line plugs.7. Please note that the adjustable frequency drive has more voltage inputs than L1, L2 and L3when load sharing (linking of DC intermediate circuit) and external 24 V DC have been installed.Make sure that all voltage inputs have been disconnected and that the necessary time has passedbefore commencing repair work.

Installation at High Altitudes

At altitudes higher than 6,600 feet [2 km], please contact Danfoss Drives regardingPELV.

Warning against Unintended Start1. The motor can be brought to a stop by means of digital commands, bus commands, referencesor a local stop while the adjustable frequency drive is connected to line power. If personal safetyconsiderations make it necessary to ensure that no unintended start occurs, these stop functionsare not sufficient. 2. While parameters are being changed, the motor may start. Consequently,the stop key [STOP/RESET] must always be activated, following which data can be modified. 3.A motor that has been stopped may start if faults occur in the electronics of the adjustable fre-

VLT AQUA Drive Design Guide 2. Introduction to the VLT AQUA Drive


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quency drive, or if a temporary overload or a fault in the supply line or the motor connectionceases.

Warning:Touching the electrical parts may be fatal - even after the equipment has been dis-connected from line power.

Also, make sure that other voltage inputs have been disconnected, such as external 24 V DC, loadsharing (linkage of DC intermediate circuit), as well as the motor connection for kinetic backup.

Refer to VLT AQUA Drive Instruction Manual MG.20.MX.YY for further safety guidelines.

2.1.2. Caution

The adjustable frequency drive DC link capacitors remain charged after power hasbeen disconnected. To avoid the risk of electric shock, disconnect the adjustablefrequency drive from line power before performing maintenance procedures. Waitat least as long as follows before servicing the adjustable frequency drive:

Voltage Min. Waiting Time4 min. 15 min.

200 - 240 V 1.5-4 hp [1.1-3.7 kW] 7.5-60 hp [5.5-45 kW]

380 - 480 V 1.5-10 hp [1.1-7.5 kW] 15-125 hp [11-90 kW]

Be aware that there may be high voltage on the DC link even when the LEDs are turned off.

2.1.3. Disposal Instructions

Equipment containing electrical components may not be disposed oftogether with domestic waste.It must be collected separately as electrical and electronic waste inaccordance with local and currently valid legislation.

2. Introduction to the VLT AQUA Drive VLT AQUA Drive Design Guide


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2.2. Software Version

VLT AQUA DriveDesign Guide

Software version: 1.00

This Design Guide can be used for all VLT AQUA adjustable frequency drives with softwareversion 1.00.The software version number can be seen in parameter 15-43.

2.3. CE labeling

2.3.1. CE Conformity and Labeling

What is CE Conformity and Labeling?The purpose of CE labeling is to avoid technical trade obstacles within the EFTA and the EU. TheEU has introduced the CE label as a simple way of showing whether a product complies with therelevant EU directives. The CE label says nothing about the specifications or quality of the product.Adjustable frequency drives are regulated by three EU directives:The machinery directive (98/37/EEC)All machines with critical moving parts are covered by the Machinery Directive of January 1, 1995.Since an adjustable frequency drive is largely electrical, it does not fall under the Machinery Di-rective. However, if an adjustable frequency drive is supplied for use in a machine, we provideinformation on its safety aspects in the manufacturer's declaration.The low-voltage directive (73/23/EEC)Adjustable frequency drives must be CE-labeled in accordance with the Low-voltage Directive ofJanuary 1, 1997. The directive applies to all electrical equipment and appliances used in the50-1000 V AC and the 75-1500 V DC voltage ranges. Danfoss uses CE labels in accordance withthe directive and will issue a declaration of conformity upon request.The EMC directive (89/336/EEC)EMC is short for electromagnetic compatibility. The presence of electromagnetic compatibilitymeans that the mutual interference between different components/appliances does not affect theway the appliances work.The EMC directive came into effect January 1, 1996. Danfoss uses CE labels in accordance withthe directive and will issue a declaration of conformity upon request. To carry out EMC-correctinstallation, see the instructions in this Design Guide. In addition, we specify the standards withwhich our products comply. We offer the filters presented in the specifications and provide othertypes of assistance to ensure the optimum EMC result.

The adjustable frequency drive is most often used by professionals of the trade as a complexcomponent forming part of a larger appliance, system or installation. It must be noted that theresponsibility for the final EMC properties of the appliance, system or installation rests with theinstaller.



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2.3.2. What Is Covered

The EU "Guidelines on the Application of Council Directive 89/336/EEC" outline three typical sit-uations of using an adjustable frequency drive. See below for EMC coverage and CE labeling.

1. The adjustable frequency drive is sold directly to the end-consumer. For example, it maybe sold to a DIY market. The end-consumer is a layman. He installs the adjustable fre-quency drive himself for use with a hobby machine, a kitchen appliance, etc. For suchapplications, the adjustable frequency drive must be CE-labeled in accordance with theEMC directive.

2. The adjustable frequency drive is sold for installation in a plant. The plant is built up byprofessionals of the trade. It could be a production plant or a heating/ventilation plantdesigned and installed by professionals of the trade. Neither the adjustable frequencydrive nor the finished plant must be CE-labeled under the EMC directive. However, theunit must comply with the basic EMC requirements of the directive. This is ensured byusing components, appliances and systems that are CE-labeled under the EMC directive.

3. The adjustable frequency drive is sold as part of a complete system. The system is beingmarketed as complete and could, for example, be an air-conditioning system. The com-plete system must be CE-labeled in accordance with the EMC directive. The manufacturercan ensure CE-labeling under the EMC directive either by using CE-labeled componentsor by testing the EMC of the system. If he chooses to use only CE-labeled components,he does not have to test the entire system.

2.3.3. Danfoss VLT Adjustable Frequency Drive and CE Labeling

CE labeling is a positive feature when used for its original purpose, i.e. to facilitate trade withinthe EU and EFTA.

However, CE labeling may cover many different specifications. Thus, you must check what a givenCE label specifically covers.

The covered specifications can be very different and a CE label may therefore give the installer afalse sense of security when using an adjustable frequency drive as a component in a system oran appliance.

Danfoss CE labels the adjustable frequency drives in accordance with the low-voltage directive.This means that if the adjustable frequency drive is installed correctly, we guarantee compliancewith the low-voltage directive. Danfoss issues a declaration of conformity that confirms our CElabeling in accordance with the low-voltage directive.

The CE label also applies to the EMC directive provided that the instructions for EMC-correct in-stallation and filtering are followed. On this basis, a declaration of conformity in accordance withthe EMC directive is issued.

The Design Guide offers detailed instructions for installation to ensure EMC-correct installation.Furthermore, Danfoss specifies which our different products comply with.

Danfoss gladly provides other types of assistance that can help you obtain the best EMC result.



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2.3.4. Compliance with EMC Directive 89/336/EEC

As mentioned, the adjustable frequency drive is mostly used by professionals of the trade as acomplex component forming part of a larger appliance, system or installation. It must be notedthat the responsibility for the final EMC properties of the appliance, system or installation restswith the installer. To assist the installer, Danfoss has prepared EMC installation guidelines for thePower Drive system. The standards and test levels stated for power drive systems are compliedwith, provided that the EMC-correct instructions for installation are followed; see the sectionElectrical Installation.

2.4. Air humidity

The adjustable frequency drive has been designed to meet the IEC/EN 60068-2-3 standard, EN50178 pkt. 9.4.2.2 at 122 F [50 C].

2.5. Aggressive Environments

An adjustable frequency drive contains a large number of mechanical and electronic components.All are vulnerable to environmental effects to some extent.

The adjustable frequency drive should not be installed in environments with airborneliquids, particles or gases capable of affecting and damaging the electronic compo-nents. Failure to take the necessary protective measures increases the risk ofstoppages, thus reducing the life of the adjustable frequency drive.

Liquids can be carried through the air and condense in the adjustable frequency drive and maycause corrosion of components and metal parts. Steam, oil and salt water may cause corrosionof components and metal parts. In such environments, use equipment with enclosure rating IP55. As an extra protection, coated printet circuit boards can be ordered as an option.

Airborne particles such as dust may cause mechanical, electrical or thermal failure in the adjustablefrequency drive. A typical indicator of excessive levels of airborne particles is the presence of dustparticles around the adjustable frequency drive fan. In very dusty environments, use equipmentwith enclosure rating IP 55 or a cabinet for IP 00/IP 20/TYPE 1 equipment.

In environments with high temperatures and humidity, corrosive gases such as sulfur, nitrogenand chlorine compounds will cause chemical processes on the adjustable frequency drive com-ponents.

Such chemical reactions will rapidly affect and damage the electronic components. In such envi-ronments, mount the equipment in a cabinet with fresh air ventilation, keeping aggressive gasesaway from the adjustable frequency drive.An extra protection in such areas is a coating of the printed circuit boards, which can be orderedas an option.



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NOTEMounting adjustable frequency drives in aggressive environments increases the riskof stoppages and considerably reduces the life of the drive.

Before installing the adjustable frequency drive, check the ambient air for liquids, particles andgases. This is done by observing existing installations in this environment. A typical indicator ofharmful airborne liquids is the presence of water or oil on metal parts, or the corrosion of metalparts.

Excessive dust particle levels are often found on installation cabinets and existing electrical in-stallations. One indicator of aggressive airborne gases is the blackening of copper rails and cableends on existing installations.

2.6. Vibration and shock

The adjustable frequency drive has been tested according to the procedure based on the shownstandards:

The adjustable frequency drive complies with requirements that exist for units mounted on thewalls and floors of production premises, as well as in panels bolted to walls or floors.

IEC/EN 60068-2-6: Vibration (sinusoidal) - 1970IEC/EN 60068-2-64: Vibration, broad-band random

2.7. Advantages

2.7.1. Why use an adjustable frequency drive for controlling fans andpumps?

An adjustable frequency drive takes advantage of the fact that centrifugal fans and pumps followthe laws of proportionality for such fans and pumps. For further information, see The Laws ofProportionality text.

2.7.2. The clear advantage - energy savings

The very clear advantage of using an adjustable frequency drive for controlling the speed of fansor pumps lies in the electricity savings.Compared to alternative control systems and technologies, an adjustable frequency drive is theoptimum energy control system for controlling fan and pump systems.

2.7.3. Example of energy savings

As can be seen from the figure (the laws of proportionality), the flow is controlled by changingthe rpm. By reducing the rated speed by only 20%, the flow is also reduced by 20%. This isbecause the flow is directly proportional to the rpm. The consumption of electricity, however, isreduced by 50%.



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If the system in question only needs to be able to supply a flow corresponding to 100% a fewdays each year, while the average is below 80% of the rated flow for the remainder of the year,the amount of energy saved is even greater than 50%.

The laws of proportionality

This figure describes the dependence of flow, pressure and power consumption on rpm.

Q = Flow P = PowerQ1 = Rated flow P1 = Rated powerQ2 = Reduced flow P2 = Reduced power

H = Pressure n = Speed regulationH1 = Rated pressure n1 = Rated speedH2 = Reduced pressure n2 = Reduced speed

Flow :Q1Q2

=n1n2

Pressure :H1H2

= ( n1n2 )2

Power :P1P2

= ( n1n2 )3

2.7.4. Example with varying flow over 1 year

The example below is calculated on the basis of pump characteristics obtained from a pump da-tasheet.The result obtained shows energy savings in excess of 50% at the given flow distribution over ayear. The pay back period depends on the price per kwh and the price of the adjustable frequencydrive. In this example, it is less than a year when compared with valves and constant speed.



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Pump characteristics Energy savings

Pshaft=Pshaft output

Flow distribution over 1 year

m3/h Distribution Valve regulation Adjustable frequency drivecontrol

% Hours Power Consumption Power ConsumptionA1 - B1 kWh A1 - C1 kWh

350 5 438 42,5 18.615 42,5 18.615300 15 1314 38,5 50.589 29,0 38.106250 20 1752 35,0 61.320 18,5 32.412200 20 1752 31,5 55.188 11,5 20.148150 20 1752 28,0 49.056 6,5 11.388100 20 1752 23,0 40.296 3,5 6.132 100 8760 275.064 26.801

2.7.5. Better control

If an adjustable frequency drive is used for controlling the flow or pressure of a system, improvedcontrol is obtained.An adjustable frequency drive can vary the speed of the fan or pump, thereby obtaining variablecontrol of flow and pressure.Furthermore, an adjustable frequency drive can quickly adapt the speed of the fan or pump tonew flow or pressure conditions in the system.Simple control of process (flow, level or pressure) utilizing the built-in PID control.



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2.7.6. Cos compensation

Generally speaking, an adjustable frequency drive with a cos of 1 provides power factor cor-rection for the cos of the motor, which means that there is no need to make allowance for thecos of the motor when sizing the power factor correction unit.

2.7.7. Star/delta starter or soft-starter not required

When larger motors are started, it is necessary in many countries to use equipment that limits thestart-up current. In more traditional systems, a star/delta starter or soft-starter is widely used.Such motor starters are not required if an adjustable frequency drive is used.

As illustrated in the figure below, an adjustable frequency drive does not consume more than ratedcurrent.

1 = VLT AQUA Drive2 = Star/delta starter

3 = Soft-starter4 = Start directly on line power



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2.8. VLT AQUA Controls

2.8.1. Control Principle

An adjustable frequency drive rectifies AC voltage from line into DC voltage, after which DC voltageis converted into an AC current with a variable amplitude and frequency.

The motor is supplied with variable voltage / current and frequency, which enables infinitely var-iable speed control of three-phased, standard AC motors.

2.8.2. Control Structure

Control structure in open-loop and closed-loop configurations:

In the configuration shown in the illustration above, par. 1-00 is set to Open-loop [0]. The resultingreference from the reference handling system is received and fed through the ramp limitation andspeed limitation before being sent to the motor control. The output of the motor control is thenlimited by the maximum frequency limit.

Select Closed-loop [3] in par. 1-00 to use the PID controller for closed-loop control of, e.g., flow,level or pressure in the controlled application. The PID parameters are located in par. group 20-**.

2.8.3. Local (Hand On) and Remote (Auto On) Control

The adjustable frequency drive can be operated manually via the local control panel (LCP) orremotely via analog and digital inputs and serial bus.If allowed in par. 0-40, 0-41, 0-42, and 0-43, it is possible to start and stop the adjustable fre-quency drive via the LCP using the [Hand ON] and [Off] keys. Alarms can be reset via the [RESET]key. After pressing the [Hand On] key, the adjustable frequency drive goes into hand mode andfollows (as default) the local reference set by using the LCP arrow keys.



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After pressing the [Auto On] key, the adjust-able frequency drive goes into auto mode andfollows (as default) the remote reference. Inthis mode, it is possible to control the adjust-able frequency drive via the digital inputs andvarious serial interfaces (RS-485, USB, or anoptional serial communication bus). See moreabout starting, stopping, changing ramps andparameter set-ups, etc. in par. group 5-1*(digital inputs) or par. group 8-5* (serial com-munication).

130BP046.10

Active Reference and ConfigurationMode

The active reference can be either the localreference or the remote reference.

In par. 3-13 Reference Site, the local refer-ence can be permanently selected by selectingLocal [2].To permanently select the remote reference,select Remote [1]. By selecting Linked toHand/Auto [0] (default), the reference site willdepend on which mode is active. (Hand Modeor Auto Mode).

Hand OffAutoLCP Keys

Reference SitePar. 3-13

Active Reference

Hand Linked to Hand/Auto LocalHand -> Off Linked to Hand/Auto LocalAuto Linked to Hand/Auto RemoteAuto -> Off Linked to Hand/Auto RemoteAll keys Local LocalAll keys Remote Remote

The table shows under which conditions either the local reference or the remote reference isactive. One of them is always active, but both cannot be active at the same time.

Par. 1-00 Configuration Mode determines what kind of application control principle (i.e., open-loop or closed-loop) is used when the remote reference is active (see table above for theconditions).



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Reference Handling - Local Reference

2.9. PID

2.9.1. Closed-loop (PID) Controller

The drives closed-loop controller allows the drive to become an integral part of the controlledsystem. The drive receives a feedback signal from a sensor in the system. It then compares thisfeedback to a setpoint reference value and determines the error, if any, between these two signals.It then adjusts the speed of the motor to correct this error.

For example, consider a pump application where the speed of a pump is to be controlled so thatthe static pressure in a pipe is constant. The desired static pressure value is supplied to the driveas the setpoint reference. A static pressure sensor measures the actual static pressure in the pipeand supplies this to the drive as a feedback signal. If the feedback signal is greater than thesetpoint reference, the drive will slow down to reduce the pressure. In a similar way, if the pipepressure is lower than the setpoint reference, the drive will automatically speed up to increasethe pressure provided by the pump.

NOTEWhile the default values for the drives closed-loop controller will often provide sat-isfactory performance, the control of the system can often be optimized by adjustingsome of the closed-loop controllers parameters. It is also possible to autotune thePI constants.

The figure is a block diagram of the drives closed-loop controller. The details of the referencehandling block and feedback handling block are described in their respective sections below.



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The following parameters are relevant for a simple PID control application:

Parameter Description of functionFeedback 1 Source par. 20-00 Select the source for Feedback 1. This is most commonly an

analog input, but other sources are also available. Use thescaling of this input to provide the appropriate values for thissignal. By default, Analog Input 54 is the default source forFeedback 1.

Reference/Feed-back Unit

par 20-12 Select the unit for the setpoint reference and feedback forthe drives closed-loop controller. Note: Because a conver-sion can be applied to the feedback signal before it is usedby the closed-loop controller, the reference/feedback unit(par. 20-12) may not be the same as the feedback sourceunit (par. 20-02, 20-05 and 20-08).

PID Normal/InverseControl

par. 20-81 Select Normal [0] if the speed of the motor should decreasewhen the feedback is greater than the setpoint reference.Select Inverse [1] if the speed of the motor should increasewhen the feedback is greater than the setpoint reference.

PID ProportionalGain

par. 20-93 This parameter adjusts the output of the drives closed-loopcontrol based on the error between the feedback and thesetpoint reference. Quick controller response is obtainedwhen this value is large. However, if a value that is too largeis used, the drives output frequency may become unstable.

PID Integral Time par. 20-94 Over time, the integrator adds (integrates) the error betweenthe feedback and the setpoint reference. This is required toensure that the error approaches zero. Quick controller re-sponse is obtained when this value is small. However, if avalue that is too small is used, the drives output frequencymay become unstable. A setting of 10,000 s disables the in-tegrator.

This table summarizes the parameters that are needed to set up the drives closed-loop controllerwhen a single feedback signal with no conversion is compared to a single setpoint. This is themost common type of closed-loop controller.



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2.9.2. Closed-loop Control Relevant Parameters

The drives closed-loop controller is capable of handling more complex applications, such as sit-uations where a conversion function is applied to the feedback signal, or where multiple feedbacksignals and/or setpoint references are used. The table below summarizes the additional parame-ters that may be useful in such applications.

Parameter Par. No. Description of functionFeedback 2 SourceFeedback 3 Source

20-0320-06

Select the source, if any, for Feedback 2 or 3. This is most commonly adrive analog input, but other sources are also available. Par. 20-20 deter-mines how multiple feedback signals will be processed by the drivesclosed-loop controller. By default, these are set to No function [0].

Feedback 1 ConversionFeedback 2 ConversionFeedback 3 Conversion

20-0120-0420-07

These are used to convert the feedback signal from one type to another,such as from pressure to flow, for example.Flow = Pressure

Reference Feedback 20-12 For setting the unit used for setpoint reference and feedback.Feedback Function 20-20 When multiple feedbacks or setpoints are used, this determines how they

will be processed by the drives closed-loop controller.Setpoint 1Setpoint 2Setpoint 3Setpoint Adjustment Factor

20-2120-2220-2320-29

These setpoints can be used to provide a setpoint reference to the drivesclosed-loop controller. Par. 20-20 determines how multiple setpoint refer-ences will be processed. Any other references that are activated in par.group 3-1* will add to these values.Par. 20-29 can be used to reduce the setpoint at low flow benefiting froma reduced pipe resistance at reduced flow.

PID Start Speed [RPM]PID Start Speed [Hz]

20-8220-83

The parameter that is visible will depend on the setting of par. 0-02, MotorSpeed Unit. In some applications, and after a start command, it is importantto quickly ramp the motor up to a pre-determined speed before activatingthe drives closed-loop controller. This parameter defines that startingspeed.

On Reference Bandwidth 20-84 This determines how close the feedback must be to the setpoint referencefor the drive to indicate that the feedback is equal to the setpoint.

PID Anti Windup 20-91 On [1] effectively disables the closed-loop controllers integral functionwhen it is not possible to adjust the output frequency of the drive to correctthe error. This allows the controller to respond more quickly once it canagain control the system. Off [0] disables this function, making the integralfunction stay active continuously.

PID Differentiation Time 20-95 This controls the output of the drives closed-loop controller based on therate of change of feedback. While this can provide a fast controller re-sponse, such a response is seldom needed in water systems. The defaultvalue for this parameter is Off, or 0.00 s.

PID Diff. Gain Limit 20-96 Because the differentiator responds to the rate of change of the feedback,a rapid change can cause a large, undesired change in the output of thecontroller. This is used to limit the maximum effect of the differentiator.This is not active when par. 20-95 is set to Off.

Flow CompensationSquare-linear Curve ApproximationWork Point CalculationSpeed at No-Flow [RPM]Speed at No-Flow [Hz]Speed at Design Point [RPM]Speed at Design Point [Hz]Pressure at No-Flow SpeedPressure at Rated SpeedFlow at Design PointFlow at Rated Speed

22-8022-8122-8222-8322-8422-8522-8622-8722-8822-8922-90

It is sometimes the case that it is not possible for a pressure transducer tobe placed at a remote point in the system, and it can only be located closeto the fan/pump outlet. Flow compensation operates by adjusting the set-point according to the output frequency, which is almost proportional toflow, thus compensating for higher losses at higher flow rates.These parameters are used for setting up flow compensation.

Low-pass Filter Time:Analog Input 53Analog Input 54Digital (pulse) input 29Digital (pulse) input 33

6-166-265-545-59

This is used to filter out high frequency noise from the feedback signal. Thevalue entered here is the time constant for the low-pass filter. The cut-offfrequency in Hz can be calculated as follows:

Fcut off =1

2TlowpassVariations in the feedback signal whose frequency is below Fcut-off will beused by the drives closed-loop controller, while variations at a higher fre-quency are considered to be noise and will be attenuated. Large values ofLow-pass Filter Time will provide more filtering, but may cause the con-troller to not respond to actual variations in the feedback signal.



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2.9.3. Example of Closed-loop PID Control

The following is an example of a closed-loop control for a booster pump application:

In a water distribution system, the pressure is to be maintained at a constant value. The desiredpressure is set between 0 and 10 Bar using a 0-10 volt potentiometer. The pressure sensor hasa range of 0 to 10 Bar and uses a two-wire transmitter to provide a 4-20 mA signal. The outputfrequency range of the drive is 10 to 50 Hz.

1. Start/Stop via switch connected betweenterminals 12 (+24 V) and 18.

2. Pressure reference via a potentiometer(0-10 Bar, 0-10 V) connected to terminals50 (+10 V), 53 (input) and 55 (common).

3. Pressure feedback via transmitter (0-10Bar, 4-20 mA) connected to terminal 54.Switch S202 behind the local control panelset to ON (current input).



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2.9.4. Programming Order

Function Par. no. Setting1) Make sure the motor runs properly. Do the following:Set the drive to control the motor, based ondrive output frequency.

0-02 Hz [1]

Set the motor parameters using nameplatedata.

1-2* As specified by motor nameplate

Run Automatic Motor Adaptation. 1-29 Enable complete AMA [1] and then run theAMA function.

2) Check that the motor is running in the right direction.Press the Hand On LCP key and the ^ keyto make the motor turn slowly. Make surethat the motor runs in the correct direction.

If the motor runs in the wrong direction,disconnect the power temporarily and re-verse two of the motor phases.

3) Make sure the adjustable frequency drive limits are set to safe valuesMake sure that the ramp settings are withinthe capabilities of the drive and allowedapplication operating specifications.

3-413-42

60 sec.60 sec.Depends on motor/load size!Also active in hand mode.

Prohibit the motor from reversing (if nec-essary)

4-10 Clockwise [0]

Set acceptable limits for the motor speed. 4-124-144-19

10 Hz, Motor min speed50 Hz, Motor max speed50 Hz, Drive max output frequency

Switch from open-loop to closed-loop. 1-00 Closed-loop [3]4) Configure the feedback to the PID controller.Set up Analog Input 54 as a feedback input. 20-00 Analog input 54 [2] (default)Select the appropriate reference/feedbackunit.

20-12 Bar [71]

5) Configure the setpoint reference for the PID controller.Set acceptable limits for the setpoint refer-ence.

3-023-03

0 Bar10 Bar

Set up Analog Input 53 as Reference 1Source.

3-15 Analog input 53 [1] (default)

6) Scale the analog inputs used for setpoint reference and feedback.Scale Analog Input 53 for the pressurerange of the potentiometer (0 - 10 Bar, 0 -10 V).

6-106-116-146-15

0 V10 V (default)0 Bar10 Bar

Scale Analog Input 54 for pressure sensor(0 - 10 Bar, 4 - 20 mA)

6-226-236-246-25

4 mA20 mA (default)0 Bar10 Bar

7) Tune the PID controller parameters.Adjust the drives closed-loop controller, ifneeded.

20-9320-94

See Optimization of the PID Controller be-low.

8) Finished!Save the parameter settings for the LCP forsafekeeping.

0-50 All to LCP [1]

2.9.5. Tuning the Drive Closed-loop Controller

Once the drives closed-loop controller has been set up, the performance of the controller shouldbe tested. In many cases, its performance may be acceptable using the default values of PIDProportional Gain (par. 20-93) and PID Integral Time (par. 20-94). However, in some cases it maybe helpful to optimize these parameter values to provide faster system response while still con-trolling speed overshoot.



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2.9.6. Manual PID Adjustment

1. Start the motor

2. Set par. 20-93 (PID Proportional Gain) to 0.3 and increase it until the feedback signalbegins to oscillate. If necessary, start and stop the drive, or make step changes in thesetpoint reference to attempt to cause oscillation. Next reduce the PID Proportional Gainuntil the feedback signal stabilizes. Then reduce the proportional gain by 40-60%.

3. Set par. 20-94 (PID Integral Time) to 20 sec. and reduce it until the feedback signalbegins to oscillate. If necessary, start and stop the drive, or make step changes in thesetpoint reference to attempt to cause oscillation. Next, increase the PID Integral Timeuntil the feedback signal stabilizes. Then increase the Integral Time by 15-50%.

4. Par. 20-95 (PID Differentiation Time) should only be used for very fast-acting systems.The typical value is 25% of the PID Integral Time (par. 20-94). The differentiator shouldonly be used when the setting of the proportional gain and the integral time has beenfully optimized. Make sure that oscillations of the feedback signal are sufficiently damp-ened by the low-pass filter for the feedback signal (par 6 16, 6 26, 5 54 or 5 59, asrequired).

2.9.7. Ziegler Nichols Tuning Method

In general, the above procedure is sufficient for water applications. However, other, more so-phisticated procedures can also be used. The Ziegler Nichols tuning method is a technique thatwas developed in the 1940s and is still commonly used today. It generally provides acceptablecontrol performance using a simple experiment and parameter calculation.

NOTEThis method must not be used on applications that could be damaged by oscillationscreated by marginally stable control settings.

2.1: Figure 1: Marginally stable system

1. Select proportional control only. That is, PID Integral Time (par. 20-94) is set to Off(10,000 s), and the PID Differentiation Time (par. 20-95) is also set to Off (0 s in thiscase).

2. Increase the value of the PID Proportional Gain (par 20-93) until the point of instabilityis reached, as indicated by sustained oscillations of the feedback signal. The PID Pro-portional Gain that causes sustained oscillations is called the critical gain, Ku.

3. Measure the period of oscillation, Pu.



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NOTE: Pu should be measured when the amplitude of oscillation is relatively small. Theoutput must not saturate (i.e., the maximum or minimum feedback signal must not bereached during the test).

4. Use the table below to calculate the necessary PID control parameters.

Type of Control Proportional Gain Integral Time DifferentiationTime

PI-control 0.45 * Ku 0.833 * Pu -PID tight control 0.6 * Ku 0.5 * Pu 0.125 * PuPID some overshoot 0.33 * Ku 0.5 * Pu 0.33 * Pu

Ziegler Nichols tuning for regulator, based on a stability boundary.Experience has shown that the control setting according to the Ziegler Nichols rule provides agood closed-loop response for many systems. If necessary, the operator can perform the finaltuning of the control iteratively in order to modify the response of the control loop.



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2.9.8. Reference Handling

A block diagram of how the drive produces the remote reference is shown below.

The Remote Reference is comprised of:

Preset references.

External references (analog inputs, pulse frequency inputs, digital potentiometer inputsand serial communication bus references).

The preset relative reference.

Feedback controlled setpoint.

Up to 8 preset references can be programmed in the drive. The active preset reference can beselected using digital inputs or the serial communications bus. The reference can also be suppliedexternally, most commonly from an analog input. This external source is selected by one of the 3reference source parameters (par. 3-15, 3-16 and 3-17). Digipot is a digital potentiometer. Thisis also commonly called a speed up/slow control, or a floating point control. To set it up, one digital



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input is programmed to increase the reference, while another digital input is programmed to de-crease the reference. A third digital input can be used to reset the digipot reference. All referenceresources and the bus reference are added to produce the total external reference. The externalreference, the preset reference or the sum of the two can be selected to be the active reference.Finally, this reference can be scaled by using the preset relative reference (par. 3-14).

The scaled reference is calculated as follows:

Reference = X + X ( Y100 )Where X is the external reference, the preset reference or the sum of these, and Y is the presetrelative reference (par. 3-14) in [%].

NOTEIf Y, the preset relative reference (par. 3-14), is set to 0%, the reference will not beaffected by the scaling

2.9.9. Feedback Handling

A block diagram of how the drive processes the feedback signal is shown below.

Feedback handling can be configured to work with applications requiring advanced control, suchas multiple setpoints and multiple feedbacks. Three types of control are common.

Single Zone, Single SetpointSingle Zone, Single Setpoint is a basic configuration. Setpoint 1 is added to any other reference(if any, see Reference Handling), and the feedback signal is selected using par. 20-20.

Multi-zone, Single SetpointMulti-zone, Single Setpoint uses two or three feedback sensors, but only one setpoint. The feed-backs can be added, subtracted (only feedback 1 and 2) or averaged. In addition, the maximumor minimum value may be used. Setpoint 1 is used exclusively in this configuration.



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Multi-zone, Multi-setpointapplies an individual setpoint reference to each feedback. The drives closed-loop controller choo-ses one pair to control the drive based on the users selection in par. 20-20. If Multi-setpointMax [14] is selected, the setpoint/feedback pair with the smallest difference controls the speedof the drive. (Note that a negative value is always smaller than a positive value).

If Multi-setpoint Min [13] is selected, the setpoint/feedback pair with the largest difference controlsthe speed of the drive. Multi-setpoint Maximum [14] attempts to keep all zones at or below theirrespective setpoints, while Multi-setpoint Min [13] attempts to keep all zones at or above theirrespective setpoints.

Example:A two-zone two setpoint application Zone 1 setpoint is 15 bar and the feedback is 5.5 bar. Zone2 setpoint is 4.4 bar and the feedback is 4.6 bar. If Multi-setpoint Max [14] is selected, Zone 1ssetpoint and feedback are sent to the PID controller, since this has the smaller difference (feed-back is higher than setpoint, resulting in a negative difference). If Multi-setpoint Min [13] isselected, Zone 2s setpoint and feedback is sent to the PID controller, since this has the largerdifference (feedback is lower than setpoint, resulting in a positive difference).

2.9.10. Feedback Conversion

In some applications, it may be useful to convert the feedback signal. One example of this is usinga pressure signal to provide flow feedback. Since the square root of pressure is proportional toflow, the square root of the pressure signal yields a value proportional to the flow. This is shownbelow.



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2.10. General aspects of EMC

2.10.1. General Aspects of EMC Emissions

Electrical interference is usually conducted at frequencies in the range of 150 kHz to 30 MHz.Airborne interference from the drive system in the range of 30 MHz to 1 GHz is generated fromthe inverter, motor cable and motor.As shown in the illustration below, capacitive currents in the motor cable coupled with a high dV/dt from the motor voltage generate leakage currents.The use of a shielded motor cable increases the leakage current (see illustration below), becauseshielded cables have higher capacitance to ground than non-shielded cables. If the leakage currentis not filtered, it will cause greater interference on the line power supply in the radio frequencyrange below approximately 5 MHz. Because the leakage current (I1) is carried back to the unitthrough the shield (I 3), there will in principle only be a small electro-magnetic field (I4) from theshielded motor cable according to the below figure.

The shield reduces the radiated interference, but increases the low-frequency interference in theline power supply. The motor cable shield must be connected to the adjustable frequency driveenclosure as well as on the motor enclosure. This is best done by using integrated shield clampsso as to avoid twisted shield ends (pigtails). These increase the shield impedance at higher fre-quencies, which reduces the shield effect and increases the leakage current (I4).If a shielded cable is used for the serial communication bus, relay, control cable, signal interfaceand brake, the shield must be mounted on the enclosure at both ends. In some situations, how-ever, it will be necessary to break the shield to avoid current loops.

If the shield is to be placed on a mounting plate for the adjustable frequency drive, the mountingplate must be made of metal, because the shield currents have to be conveyed back to the unit.Moreover, ensure good electrical contact from the mounting plate through the mounting screwsto the adjustable frequency driver chassis.

NOTEWhen non-shielded cables are used, some emission requirements are not compliedwith, although the immunity requirements are observed.



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In order to reduce the interference level from the entire system (unit + installation), make motorand brake cables as short as possible. Avoid placing cables with a sensitive signal level alongsidemotor and brake cables. Radio interference higher than 50 MHz (airborne) is especially generatedby the control electronics.

2.10.2. EMC Test Results (Emission, Immunity)

The following test results were obtained using a system with an adjustable frequency drive (with options, if relevant),a shielded control cable, a control box with potentiometer, as well as a motor and motor-shielded cable.RFI filter type Conducted emission Radiated emission

Industrial environment Housing,trades, and

light industries

Industrial envi-ronment

Housing, trades, andlight industries

Set-up EN 55011 ClassA2

EN 55011Class A1

EN 55011 ClassB

EN 55011 ClassA1

EN 55011 Class B

H10.34-60 hp [0.25-45 kW]

200-240 V 492 ft [150 m]492 ft [150

m] 1) 164 ft [50 m] Yes No

0.34-125 hp [0.25-90 kW]380-480 V 492 ft [150 m]

492 ft [150m] 164 ft [50 m] Yes No

H20.34-4 hp [0.25-3.7 kW]

200-240 V16 ft [5 m] No No No No

7.5-60 hp [5.5-45 kW]200-240 V 82 ft [25 m] No No No No

0.34-10 hp [0.25-7.5 kW]380-480 V

16 ft [5 m] No No No No

15-125 hp [11-90 kW]380-480 V 82 ft [25 m] No No No No

H30.34-60 hp [0.25-45 kW]

200-240 V 246 ft [75 m]164 ft [50 m]

1) 33 ft [10 m] Yes No0.34-125 hp [0.25-90 kW]

380-480 V 246 ft [75 m] 164 ft [50 m] 33 ft [10 m] Yes No

2.1: EMC Test Results (Emission, Immunity)

1) 15 hp [11 kW ]200 V, H1 and H2 performance is delivered in enclosure type B1.15 hp [11 kW] 200 V, H3 performance is delivered in enclosure type B2.

2.10.3. Required Compliance Levels

Standard / environment Housing, trades, and light indus-tries

Industrial environment

Conducted Radiated Conducted RadiatedIEC 61000-6-3 (generic) Class B Class BIEC 61000-6-4 Class A1 Class A1EN 61800-3 (restricted) Class A1 Class A1 Class A1 Class A1EN 61800-3 (unrestricted) Class B Class B Class A2 Class A2

EN 55011: Threshold values and measuring methods for radio interference from industrial,scientific and medical (ISM) high-frequency equipment.

Class A1: Equipment used in a public supply network. Restricted distribution.Class A2: Equipment used in a public supply network.Class B1: Equipment used in areas with a public supply network (residential, commerce,

and light industries). Unrestricted distribution.



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2.10.4. EMC Immunity

In order to document immunity against interference from electrical phenomena, the followingimmunity tests have been performed on a system consisting of an adjustable frequency drive (withoptions, if relevant), a shielded control cable and a control box with potentiometer, motor cableand motor.

The tests were performed in accordance with the following basic standards:

EN 61000-4-2 (IEC 61000-4-2): Electrostatic discharges (ESD) Simulation ofelectrostatic discharges from human beings.

EN 61000-4-3 (IEC 61000-4-3): Incoming electromagnetic field radiation,amplitude modulated Simulation of the effects of radar and radio communicationequipment as well as mobile communications.

EN 61000-4-4 (IEC 61000-4-4): Electrical interference Simulation of interferencecaused by switching with a contactor, relays, or similar devices.

EN 61000-4-5 (IEC 61000-4-5): Surge transients Simulation of transients caused,e.g., by lightning strikes near installations.

EN 61000-4-6 (IEC 61000-4-6): RF Common mode Simulation of the effect fromradio-transmitting equipment connected to connection cables.

See following EMC immunity form.

VLT AQUA; 200-240 V, 380-480 VBasic standard Burst

IEC 61000-4-4Surge

IEC 61000-4-5ESDIEC

61000-4-2

Radiated electromagneticfield

IEC 61000-4-3

RF commonmode voltageIEC 61000-4-6

Acceptance criterion B B B A ALine 4 kV CM 2 kV/2 DM4 kV/12 CM 10 VRMS

Motor 4 kV CM 4 kV/2 1) 10 VRMSBrake 4 kV CM 4 kV/2 1) 10 VRMSLoad sharing 4 kV CM 4 kV/2 1) 10 VRMSControl wires 2 kV CM 2 kV/2 1) 10 VRMSStandard bus 2 kV CM 2 kV/2 1) 10 VRMSRelay wires 2 kV CM 2 kV/2 1) 10 VRMSApplication and serial com-munication options

2 kV CM2 kV/2 1) 10 VRMS

LCP cable 2 kV CM 2 kV/2 1) 10 VRMSExternal 24 V DC 2 kV CM 0.5 kV/2 DM1 kV/12 CM 10 VRMS

Enclosure 8 kV AD6 kV CD 10 V/m

AD: Air DischargeCD: Contact DischargeCM: Common modeDM: Differential mode

1. Injection on cable shield.

2.2: Immunity



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2.11. Galvanic isolation (PELV)

PELV offers protection by way of extra low voltage. Protection against electric shock is ensuredwhen the electrical supply is of the PELV type and the installation is made as described in local/national regulations on PELV supplies.

All control terminals and relay terminals 01-03/04-06 comply with PELV (Protective Extra LowVoltage - does not apply to 525-600 V units and at grounded Delta leg above 300 V).

Galvanic (ensured) isolation is obtained by fulfilling requirements for higher isolation and by pro-viding the relevant creepage/clearance distances. These requirements are described in the EN61800-5-1 standard.

The components that make up the electrical isolation, as described below, also comply with therequirements for higher isolation and the relevant test as described in EN 61800-5-1.The PELV galvanic isolation can be shown in six locations (see illustration):

In order to maintain PELV, all connections made to the control terminals must be PELV. For ex-ample, the thermistor must be reinforced/double insulated.

1. Power supply (SMPS) incl. signal iso-lation of UDC, indicating the inter-mediate current voltage.

2. Gate drive that runs the IGBTs (trig-ger transformers/opto-couplers).

3. Current transducers.

4. Opto-coupler, brake module.

5. Internal soft-charge, RFI and tem-perature measurement circuits.

6. Custom relays. 2.2: Galvanic isolation

The functional galvanic isolation (a and b in drawing) is for the 24 V backup option and for theRS-485 standard bus interface.

At altitudes higher than 6,600 feet [2 km], please contact Danfoss Drives regardingPELV.



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2.12. Ground leakage current

Warning:Touching the electrical parts may be fatal - even after the equipment has been dis-connected from line power.Also make sure that other voltage inputs have been disconnected, such as loadsharing (linkage of DC intermediate circuit), as well as the motor connection forkinetic backup.Before touching any electrical parts, wait at least 15 minutes.A shorter time is allowed only if indicated on the nameplate for the specific unit.

Leakage CurrentThe ground leakage current from the adjustable frequency drive exceeds 3.5 mA.To ensure that the ground cable has a good mechanical connection to the groundconnection (terminal 95), the cable cross-section must be at least 0.016 in.2 [10mm2] or have 2 rated ground wires terminated separately.Residual Current DeviceThis product can cause DC current in the protective conductor. Where a residualcurrent device (RCD) is used for extra protection, only an RCD of Type B (time de-layed) shall be used on the supply side of this product. See also RCD ApplicationNote MN.90.Gx.yy.Protective grounding of the adjustable frequency drive and the use of RCDs mustalways follow national and local regulations.

2.13. Control with brake function

2.13.1. Selection of Brake Resistor

In certain applications, for instance, in centrifuges, it is desirable to bring the motor to a stop morerapidly than can be achieved through controlling via ramp-down or by free-wheeling. In suchapplications, dynamic braking with a braking resistor may be utilized. Using a braking resistorensures that the energy is absorbed in the resistor and not in the adjustable frequency drive.

If the amount of kinetic energy transferred to the resistor in each braking period is not known,the average power can be calculated on the basis of the cycle time and braking time, also knownas the intermitted duty cycle. The resistor intermittent duty cycle is an indication of the duty cycleat which the resistor is active. The figure below shows a typical braking cycle.

The intermittent duty cycle for the resistor is calculated as follows:

Duty Cycle = tb/T

T = cycle time in secondstb is the braking time in seconds (as part of the total cycle time)



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Danfoss offers brake resistors with a duty cycle of 5%, 10% and 40%, which are all suitable foruse with the FC202 AQUA drive series. If a 10% duty cycle resistor is applied, it is capable ofabsorbing braking energy up to 10% of the cycle time, with the remaining 90% being used todissipate heat from the resistor.

For further selection advice, please contact Danfoss.

NOTEIf a short circuit in the brake transistor occurs, power dissipation in the brake resistoris only prevented by using a line switch or contactor to disconnect the AC line forthe adjustable frequency drive. (The contactor can be controlled by the adjustablefrequency drive).

2.13.2. Control with Brake Function

The brake is to limit the voltage in the intermediate circuit when the motor acts as a generator.This occurs, for example, when the load drives the motor and the power accumulates on the DClink. The brake is built up as a chopper circuit with the connection of an external brake resistor.

Placing the brake resistor externally offers the following advantages:- The brake resistor can be selected on the basis of the application in question.

- The braking energy can be dissipated outside the control panel, i.e., where the energycan be utilized.

- The electronics of the adjustable frequency drive will not overheat if the brake resistoris overloaded.

The brake is protected against short-circuiting of the brake resistor, and the brake transistor ismonitored to ensure that short-circuiting of the transistor is detected. A relay/digital output canbe used for protecting the brake resistor against overloading in connection with a fault in theadjustable frequency drive.In addition, the brake makes it possible to read out the momentary power and the mean powerfor the last 120 seconds. The brake can also monitor the power energizing and ensure that it doesnot exceed a limit set in par. 2-12. In par. 2-13, select the function to carry out when the powertransmitted to the brake resistor exceeds the limit set in par. 2-12.



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NOTEMonitoring the braking energy is not a safety function; a thermal switch is requiredfor that purpose. The brake resistor circuit is not protected against ground leakage.

Overvoltage control (OVC) (exclusive brake resistor) can be selected as an alternative brake func-tion in par. 2-17. This function is active for all units. The function ensures that a trip can be avoidedif the DC link voltage increases. This is done by increasing the output frequency to limit the voltagefrom the DC link. It is a very useful function if, for example, the ramp-down time is too shortbecause tripping the adjustable frequency drive is avoided. In this situation, the ramp-down timeis extended.

2.14. Mechanical brake control

2.14.1. Cabling

EMC (twisted cables/shielding)To reduce the electrical noise from the wires between the brake resistor and the adjustable fre-quency drive, the wires must be twisted.

For enhanced EMC performance, a metal shield can be used.

2.15. Extreme running conditions

Short Circuit (Motor Phase Phase)The adjustable frequency drive is protected against short circuits by means of current measure-ment in each of the three motor phases or in the DC link. A short circuit between two outputphases will cause an overcurrent in the inverter. The inverter will be turned off individually whenthe short circuit current exceeds the permitted value (Alarm 16 Trip Lock).To protect the drive against a short circuit at the load sharing and brake outputs, please see thedesign guidelines.

Switching on the OutputSwitching on the output between the motor and the adjustable frequency drive is fully permitted.You cannot damage the adjustable frequency drive in any way by switching on the output. How-ever, fault messages may appear.

Motor-generated OvervoltageThe voltage in the intermediate circuit is increased when the motor acts as a generator. This occursin the following cases:

1. The load drives the motor, i.e., the load generates energy.

2. During deceleration ("ramp-down"), if the moment of inertia is high the friction is lowand the ramp-down time is too short for the energy to be dissipated as a loss in theadjustable frequency drive, the motor and the installation.

3. Incorrect slip compensation setting may cause higher DC link voltage.



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The control unit may attempt to correct the ramp if possible (par. 2-17 Overvoltage Control.The inverter turns off to protect the transistors and the intermediate circuit capacitors when acertain voltage level is reached.See par. 2-10 and par. 2-17 to select the method used for controlling the intermediate circuitvoltage level.

High TemperatureHigh ambient temperature may overheat the adjustable frequency drive.

Line Drop-outDuring a line drop-out, the adjustable frequency drive keeps running until the intermediate circuitvoltage drops below the minimum stop level, which is typically 15% below the adjustable fre-quency drive's lowest rated supply voltage.

The line voltage before the drop-out and the motor load determine how long it takes for theinverter to coast.

Static Overload in VVCplus modeWhen the adjustable frequency drive is overloaded (the torque limit in par. 4-16/4-17 is reached),the control reduces the output frequency to reduce the load.If the overload is excessive, a current may occur that makes the adjustable frequency drive cutout after approximately 5-10 s.

Operation within the torque limit is limited in time (0-60 s) in par. 14-25.



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2.15.1. Motor Thermal Protection

The motor temperature is calculated on the basis of motor current, output frequency, and timeor thermistor. See par. 1-90 in the chapter How to Program.

2.15.2. Safe Stop Operation

The FC 202 can perform the Safety Function Uncontrolled Stopping by removal of power (asdefined by draft IEC 61800-5-2) or Stop Category 0 (as defined in EN 60204-1).It is designed and deemed suitable for the requirements of Safety Category 3 in EN 954-1. Thisfunction is called safe stop.Prior to integration and use of the FC 202 Safe Stop in an installation, a thorough risk analysis onthe installation must be carried out in order to determine whether the FC 202 Safe Stop function-ality and safety category are appropriate and sufficient.The safe stop function is activated by removing the voltage at Terminal 37 of the safe inverter.By connecting the safe inverter to external safety devices providing a safe relay, an installationfor a safe Stop Category 1 can be obtained. The safe stop function of the FC 202 can be used forasynchronous and synchronous motors.

Safe stop activation (i.e., removal of 24 V DC voltage supply to terminal 37) doesnot provide electrical safety.



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NOTEThe safe stop function of the FC 202 can be used for asynchronous and synchronousmotors. It may happen that two faults occur in the adjustable frequency drive'spower semiconductor. When using synchronous motors, this may cause a residualrotation. The rotation can be calculated to Angle=360/(Number of Poles). The ap-plication using synchronous motors must take this into consideration and ensure thatthis is not a safety-critical issue. This situation is not relevant for asynchronous mo-tors.

NOTEIn order to use the safe stop functionality in conformance with the requirements ofEN-954-1 Category 3, a number of conditions must be fulfilled by the installation ofsafe stop. Please see section Safe Stop Installation for further information.

NOTEThe adjustable frequency drive does not provide safety-related protection againstunintended or malicious voltage supply to terminal 37 and subsequent reset. Providethis protection via the interrupt device, at the application level, or organizationallevel.For more information - see section Safe Stop Installation.



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3. VLT AQUA Selection VLT AQUA Drive Design Guide


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3. VLT AQUA Selection

3.1. General Specifications

3.1.1. Line Supply 3 x 200-240 V AC

Normal overload 110% for 1 minuteLine supply 200-240 V AC.Adjustable frequency driveTypical Shaft Output [kW]

PK250.25

PK370.37

PK550.55

PK750.75

Typical Shaft Output [HP] at 208 V 0.3 0.5 0.75 1.0EncapsulationIP 20 A2 A2 A2 A2IP 55 A5 A5 A5 A5IP 66 A5 A5 A5 A5Output current

Continuous(3 x 200-240 V) [A]

1.8 2.4 3.5 4.6

Intermittent(3 x 200-240 V) [A] 2.9 3.8 5.6 7.4

ContinuouskVA (208 V AC) [kVA] 0.65 0.86 1.26 1.66

Max. cable size: 24 - 10 AWG(line, motor, brake)[mm2 /AWG] 0.00031-0.0062 in. [0.2-4 mm]

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Max. input currentContinuous(3 x 200-240 V) [A] 1.6 2.2 3.2 4.1


Max. pre-fuses1) [A] 10 10 10 10EnvironmentEstimated power lossat rated max. load [W] 4)

21 29 42 54

Weight enclosure IP 20 [kg] 4.7 4.7 4.8 4.8Efficiency 4) 0.94 0.94 0.95 0.95

1. For type of fuse, see section Fuses.

2. American Wire Gauge

3. Measured using 16.4 ft. [5 m] shielded motor cables at rated load and rated frequency.

4. The typical power loss is at nominal load conditions and expected to be within +/-15%(tolerance relates to variety in voltage and cable conditions).Values are based on a typical motor efficiency (eff2/eff3 border line). Lower efficiencymotors will also add to the power loss in the adjustable frequency drive and vice versa.If the switching frequency is raised from nominal, the power losses may rise significantly.LCP and typical control card power consumption values are included. Further options andcustomer load may add up to 30W to the losses (though typically only 4W extra for afully loaded control card, or options for slot A or slot B, each).Although measurements are made with state of the art equipment, some measurementinaccuracy must be allowed for (+/- 5%).

VLT AQUA Drive Design Guide 3. VLT AQUA Selection


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P1K11.1

P1K51.5

P2K22.2

P3K03

P3K73.7

Typical Shaft Output [HP] at 208 V 1.5 2 3 4 5EncapsulationIP 20 A2 A2 A2 A3 A3IP 55 A5 A5 A5 A5 A5IP 66 A5 A5 A5 A5 A5Output current

Continuous(3 x 200-240 V) [A] 6.6 7.5 10.6 12.5 16.7

Intermittent(3 x 200-240 V) [A] 7.3 8.3 11.7 13.8 18.4

ContinuouskVA (208 V AC) [kVA] 2.38 2.70 3.82 4.50 6.00

Max. cable size:(line, motor, brake)[mm2 /AWG]

4/10

Max. input currentContinuous(3 x 200-240 V) [A] 5.9 6.8 9.5 11.3 15.0


Max. pre-fuses1) [A] 20 20 20 32 32EnvironmentEstimated power lossat rated max. load [W] 4)

63 82 116 155 185

Weight enclosure IP 20 [kg] 4.9 4.9 4.9 6.6 6.6Weight enclosure IP 21 [kg] 5.5 5.5 5.5 7.5 7.5Weight enclosure IP 55 [kg] 13.5 13.5 13.5 13.5 13.5Weight enclosure IP 66 [kg] 13.5 13.5 13.5 13.5 13.5Efficiency 4) 0.96 0.96 0.96 0.96 0.96







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P5K55.5

P7K57.5

P11K11

P15K15

Typical Shaft Output [HP] at 208 V 7.5 10 15 20EncapsulationIP 21 B1 B1 B2 B2IP 55 B1 B1 B2 B2IP 66 B1 B1 B2 B2Output current

Continuous(3 x 200-240 V) [A] 24.2 30.8 46.2 59.4


ContinuouskVA (208 V AC) [kVA] 8.7 11.1 16.6 21.4


10/7 35/2

Max. input currentContinuous(3 x 200-240 V) [A] 22.0 28.0 42.0 54.0


Max. pre-fuses1) [A] 63 63 63 80EnvironmentEstimated power lossat rated max. load [W] 4)

269 310 447 602

Weight enclosure IP 20 [kg]Weight enclosure IP 21 [kg] 23 23 23 27Weight enclosure IP 55 [kg] 23 23 23 27Weight enclosure IP 66 [kg] 23 23 23 27Efficiency 4) 0.96 0.96 0.96 0.96







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P18K18.5

P22K22

P30K30

P37K37

P45K45

Typical Shaft Output [HP] at 208 V 25 30 40 50 60EncapsulationIP 21 C1 C1 C2 C2 C2IP 55 C1 C1 C2 C2 C2IP 66 C1 C1 C2 C2 C2Output current

Continuous(3 x 200-240 V) [A] 74.8 88.0 115 143 170

Intermittent(3 x 200-240 V) [A] 82.3 96.8 127 157 187

ContinuouskVA (208 V AC) [kVA] 26.9 31.7 41.4 51.5 61.2


50/1/0 95/4/0 120/250 MCMMax. input current

Continuous(3 x 200-240 V) [A] 68.0 80.0 104.0 130.0 154.0


Max. pre-fuses1) [A] 125 125 160 200 250EnvironmentEstimated power lossat rated max. load [W] 4)

737 845 1140 1353 1636

Weight enclosure IP 20 [kg]Weight enclosure IP 21 [kg] 45 45 65 65 65Weight enclosure IP 55 [kg] 45 45 65 65 65Weight enclosure IP 66 [kg] 45 45 65 65 65Efficiency 4) 0.96 0.97 0.97 0.97 0.97







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3.1.2. Line Supply 3 x 380-480 V AC

Normal overload 110% for 1 minuteLine Supply 3 x 380-480 V ACAdjustable frequency driveTypical Shaft Output [kW]

PK370.37

PK550.55

PK750.75

P1K11.1

P1K51.5

Typical Shaft Output [HP] at 460 V 0.5 0.75 1 1.5 2Encapsulation IP 20 A2 A2 A2 A2 A2IP 21 IP 55 A5 A5 A5 A5 A5IP 66 A5 A5 A5 A5 A5Output current

Continuous(3 x 380-440 V) [A] 1.3 1.8 2.4 3 4.1


Continuous(3 x 440-480 V) [A] 1.2 1.6 2.1 2.7 3.4


Continuous kVA(400 V AC) [kVA] 0.9 1.3 1.7 2.1 2.8

Continuous kVA(460 V AC) [kVA] 0.9 1.3 1.7 2.4 2.7

Max. cable size:(line, motor, brake)[[mm2/ AWG]

4/10

Max. input currentContinuous(3 x 380-440 V) [A] 1.2 1.6 2.2 2.7 3.7


Continuous(3 x 440-480 V) [A] 1.0 1.4 1.9 2.7 3.1


Max. pre-fuses1)[A] 10 10 10 10 10EnvironmentEstimated power lossat rated max. load [W] 4)

35 42 46 58 62

Weight enclosure IP 20 [kg] 4.7 4.7 4.8 4.8 4.9Weight enclosure IP 55 [kg] 13.5 13.5 13.5 13.5 13.5Efficiency 4) 0.93 0.95 0.96 0.96 0.97







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Normal overload 110% for 1 minuteLine Supply 3 x 380-480 V ACAdjustable frequency driveTypical Shaft Output [kW]

P2K22.2

P3K03

P4K04

P5K55.5

P7K57.5

Typical Shaft Output [HP] at 460 V 3 4 5 7 10Encapsulation IP 20 A2 A2 A2 A3 A3IP 21 IP 55 A5 A5 A5 A5 A5IP 66 A5 A5 A5 A5 A5Output current

Continuous(3 x 380-440 V) [A] 5.6 7.2 10 13 16

Intermittent(3 x 380-440 V) [A] 6.2 7.9 11 14.3 17.6

Continuous(3 x 440-480 V

VLTAquaDesignGuide(130R0337)

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